Nordyne TE 95 Installation Instructions Manual

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Page 1

Gas Fired Central Furnaces

Installation Instructions

*TE Series 95+ Upﬂ ow/Horizontal Two-Stage Furnace for

95+

Upﬂ ow/Horizontal

Furnace

Systems

NOTE: This furnace must be installed by qualiﬁ ed installers who are specially

trained on the NORDYNE iQ DRIVE

WARNING:

Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual for assistance. For additional information consult a qualiﬁ ed installer, service agency, or the gas supplier.

These instructions are primarily intended to assist qualiﬁ ed individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Read all instructions carefully before starting the installation.

DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

SYSTEM.

Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the ﬁ re department.

• Extinguish any open ﬂ ame.

FOR YOUR SAFETY:

Page 2

Table of Contents

Furnace Speciﬁ cations ................................................................................................................................. 3, 4

Safety Information ............................................................................................................................................. 4

Installation Requirements ................................................................................................................................. 4

Clearances to Combustible Materials .............................................................................................................. 5

Important Note - Commonwealth of Massachusetts .................................................................................. 4, 5

Location .............................................................................................................................................................. 6

Horizontal Installations ..................................................................................................................................... 6

Conversion of the iQ Drive Upﬂ ow Furnace for a Horizontal Right Installation .......................................... 6

Conversion of the iQ Drive Upﬂ ow Furnace for a Horizontal Left Installation ............................................. 7

Circulating Air Supply ....................................................................................................................................... 8

Return Air ................................................................................................................................................... 8

Determining Nominal AC System Capacity ................................................................................................ 8

Selecting the AC Cooling Airﬂ ow ................................................................................................................ 9

Selecting the Heating Airﬂ ow ..................................................................................................................... 9

Venting and Combustion Air Requirements ................................................................................................... 9

Air Requirements for One-Pipe Installation .............................................................................................. 10

Installation in An Unconﬁ ned Space......................................................................................................... 10

Installation in A Conﬁ ned Space .............................................................................................................. 10

• Air From Inside ....................................................................................................................................... 10

• Air Directly Through An Exterior Wall ..................................................................................................... 10

• Outdoor Air Through Vertical Openings or Ducts ................................................................................... 10

• Outdoor Air Through Horizontal Openings or Ducts .............................................................................. 11

Venting Requirements ..................................................................................................................................... 11

Vent Pipe Material .................................................................................................................................... 13

Vent Pipe Length and Diameter ............................................................................................................... 15

Vent Pipe Installation ................................................................................................................................ 15

Pipe Routing & Support ............................................................................................................................ 15

Location of Outdoor Terminations ............................................................................................................ 18

Horizontal Venting ................................................................................................................................... 18

Vertical Venting ......................................................................................................................................... 19

Vent Freezing Protection .......................................................................................................................... 19

Concentric Vent Termination ..................................................................................................................... 20

Drainage of Condensate From Furnace ........................................................................................................ 20

Gas Supply and Piping ................................................................................................................................... 21

Leak Check ............................................................................................................................................. 21

Manifold Pressure Adjustment ................................................................................................................. 22

Conversion ............................................................................................................................................... 22

High Altitude Conversion ................................................................................................................................24

High Altitude Application .......................................................................................................................... 24

Pressure Switch Conversion for High Altitude Applications ..................................................................... 24

Natural Gas High Altitude Conversion ...................................................................................................... 24

LP/Propane Gas Sea Level and High Altitude Conversion ...................................................................... 24

Electrical Wiring ............................................................................................................................................... 25

Line Voltage Wiring ................................................................................................................................... 25

Low Voltage Wiring ................................................................................................................................... 25

Start-up and Adjustments............................................................................................................................... 26

Start-Up Procedures ................................................................................................................................ 27

Verifying and Adjusting Firing Rate .......................................................................................................... 27

Selecting the Cooling Airﬂ ow .................................................................................................................... 28

Verifying and Adjusting Temperature Rise ................................................................................................ 29

Verifying Burner Operation ....................................................................................................................... 29

Verifying Operation of the Supply Air Limit Switch ................................................................................... 29

Wiring Diagram......................................................................................................................................... 31

Description of Components ........................................................................................................................... 30

Maintenance ..................................................................................................................................................... 30

Combustion Air and Vent System ............................................................................................................. 32

Air Filter(s) ................................................................................................................................................ 32

Lubrication ................................................................................................................................................ 32

Location of Major Components ...................................................................................................................... 33

Condensate Drain Assembly .................................................................................................................... 32

Blower Compartment ............................................................................................................................... 32

Heat Exchanger and Burner Maintenance ............................................................................................... 32

System Operation Information ....................................................................................................................... 34

Sequence of Operation ............................................................................................................................ 34

Furnace Fails to Operate .......................................................................................................................... 35

Installation/Performance Checklist ................................................................................................................ 36

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FURNACE SPECIFICATIONS

23"

27 5/8"

25 5/8"

1 1/2" x 3 1/2" Dia.

Opening for

Gas Connection

7/8" Dia. Electric

Connection

Bottom Return Opening

25 1/4"

2" PVC

Exhaust

Vent

(See Fig. 15

for sizes)

3/4"

2 1/4"

‡

30 1/4"

‡

(Bottom)

‡

Return Air Opening

Condensate Drain Outlets

3/4"

See Table 1

‡

Combustion Air

Vent 3"

Inlet

23 1/4"

Combustion Air

22 1/2"

Exhaust Vent

3/4"

Upﬂ ow/Horizontal Furnace Models

3/4"

Figure 1. Upﬂ ow/Horizontal Unit Dimensions

(See Fig. 15

for sizes)

19 3/4"

25 1/8"

Opening for

Gas Connection

1 1/2" x 3 1/2" Dia.

33"

25 1/4"

Connection

7/8" Dia. Electric

43"

20 1/2"

15"

28"

23"

Side Return

1 1/4"

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SAFETY INFORMATION

INSTALLATION REQUIREMENTS

1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate.

2. Install this furnace only in a location and position as speciﬁ ed on Tables 1 and 2 of these instructions.

3. Provide adequate combustion and ventilation air to the furnace space as speciﬁ ed on Pages 10 through 14.

4. Provisions for adequate clearances around the vent air intake terminal(s) as speciﬁ ed on Figures 13 through 17 of these instructions.

5. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as speciﬁ ed on Pages 14 through 22.

6. Never test for gas leaks with an open ﬂ ame. Use a commercially available soap solution made speciﬁ cally for the detection of leaks to check all connections, as speciﬁ ed on Page 25 of these instructions.

7. Always install furnace to operate within the furnace’s intended temperature-rise range with a duct system which has an external static pressure within the allowable range, see furnace rating plate.

8. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

9. A gas-ﬁ red furnace for installation in a residential garage must be installed as speciﬁ ed on Page 7 of these instructions.

10. The furnace is not to be used for temporary heating of buildings or structures under construction.

Requirements and Codes

This furnace must be installed in accordance with these instructions, all applicable local building codes, and the current revision of the National Fuel Gas Code (ANSI-Z223.1, NFPA-54). The current revision of the National Fuel Gas Code is available from: American National Standards Institute, Inc. 1430 Broadway New York, New York 10018 Canada installations shall comply with CAN/ CGA-B149 installation codes, local plumbing or waste water codes and other applicable codes. Additional helpful publications are:

• NFPA-90A - Installation of Air Conditioning and Ventilating Systems.

• NFPA-90B - Warm Air Heating and Air Conditioning Systems.

These publications are available from: National Fire Protection Association, Inc. Batterymarch Park Quincy, Massachusetts 02269

WARNING:

This furnace is not approved for installation in mobile homes. Installation in a mobile home could cause ﬁ re, property damage, and/or personal injury.

IMPORTANT NOTE

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR

4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows:

Model

Number

*TE060 60,000 42,000 35-65 35-65 19 3/4 18 1/4 7 7/8 17 1/4 195

*TE080 80,000 56,000 30-60 30-60 19 3/4 18 1/4 7 7/8 17 1/4 195

*TE100 100,000 70,000 40-70 40-70 19 3/4 18 1/4 7 7/8 17 1/4 200

*TE120 120,000 84,000 45-70 45-75 22 1/2 21 9 1/4 20 220

High Fire

Furnace

Low Fire Furnace

Table 1. Furnace Dimensions and Shipping Weights

Temperature Rise Range,

°F

1st Stage 2nd Stage A B C D

Dimensions (inches)

Shipping

Weight

(lbs)

Page 5

(a) For direct-vent appliances, mechanical-

vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisﬁ ed:

1. If there is not one already present, on each ﬂ oor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall be located in the room that houses the appliance or equipment and shall:

a. Be powered by the same electrical

circuit as the appliance or equipment such that only one service switch services both the appliance and the

carbon monoxide detector; b. Have battery back-up power; c. Meet ANSI/UL 2034 Standards and

comply with NFPA 720 (2005 Edi-

tion); and d. Have been approved and listed by

a Nationally Recognized Testing

Laboratory as recognized under 527

CMR.

3. A Product-approved vent terminal must be used, and if applicable, a Productapproved air intake must be used. Installation shall be in strict compliance

with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.

4. A metal or plastic identiﬁ cation plate shall be mounted at the exterior of the building, four feet directly above the location of vent terminal. The plate shall be of sufﬁ cient size to be easily read from a distance of eight feet away, and read “Gas Vent Directly Below”.

(b) For direct-vent appliances, mechanical-

vent heating appliances or domestic hot water equipment where the bottom of the vent terminal and the air intake is installed above four feet above grade the following requirements must be satisﬁ ed:

2. A carbon monoxide detector shall:

a. Be located in the room that houses

the appliance or equipment;

b. Be either hard-wired or battery pow-

ered or both; and

c. Shall comply with NFPA 720 (2005

Edition).

CLEARANCES TO COMBUSTIBLE MATERIALS

This furnace is Designed Certiﬁ ed by CSA International for the minimum clearances to combustible material listed in Table 6. See the furnace name plate, located inside the furnace cabinet, for speciﬁ c model number and clearance information.

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIAL

High Fire

Rated Input

(Btuh)

60,000 14 1/2 00011

60,000 19 3/4 00011

80,000 19 3/4 00011

100,000 19 3/4 00011

120,000 22 1/2 00011

‡

24 inches is the minimum clearance for servicing.

36 inches is the recommended clearance for service.

Cabinet

Width

(Inches)

Table 2. Minimum Clearances to Combustible Materials

Minimum Clearances (Inches)

Side Vent Back Top Front

‡

Page 6

3. A Product-approved vent terminal must be used, and if applicable, a Productapproved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.

Location

The furnace must be installed on a level surface, and as close to the center of the air distribution system as possible. See Table 1 for overall dimensions to determine the required clearances in hallways, doorways, stairs, etc. to allow the furnace to be moved to the installation point. The furnace must be installed so that all electrical components are protected from water.

Minimum clearances to combustible materials are listed in Table 2. Access for positioning and servicing must be considered when locating the unit. 24 inches is the minimum required clearance for servicing the unit. 30 inches is the minimum required clearance for positioning the unit. 36 inches is the recommended clearance from the front of the unit. Please note that a panel or door can be located such that the minimum clearance on the rating plate is satisﬁ ed, but that panel or door must be removable so as to allow the appropriate clearance.

This furnace is certiﬁ ed for use on wood ﬂ ooring. The furnace must be installed on a solid surface and must be level front to back and side to side. This furnace must not be installed directly on carpeting, tile, or any combustible material other than wood ﬂ ooring.

A gas-ﬁ red furnace installed in a residential garage must be installed so that the bottom of the burners and igniter are located a minimum of 18” from the ﬂ oor. The furnace must be located or protected to avoid physical damage by vehicles.

HORIZONTAL INSTALLATIONS

The upﬂ ow model furnaces are approved for horizontal installation. Installation Kit #903568 is available for horizontal applications. The parts may also be ﬁ eld supplied. The parts that are ﬁ eld supplied should conform to Figures 2 and 3.

CAUTION:

Damage to the product resulting from failure to follow instructions or use of unauthorized parts may void the manufacturer’s product warranty coverage.

The 90+ upﬂ ow furnace can be installed horizontally in an attic, basement, crawl space or alcove. This furnace can be installed horizontally to the clearances listed in Table 6 on a platform or on the ceiling rafters. Note that the platform and the ceiling rafters must be able to support the weight of the furnace being installed. It can also be suspended from a ceiling in a basement or utility room in either a right to left airﬂ ow or left to right airﬂ ow.

When installed horizontally, the furnace must be raised above the surface to allow a drain trap to hang vertically below the furnace. This will allow for proper drainage of the condensate from the furnace.

Conversion of the iQ Drive Upﬂ ow Furnace for a Horizontal Right Installation.

Refer to Figure 2.

1. Remove the hard “J” tube drain trap assembly.

2. Place the 5/8” cap plug over the drain trap in the header box from which the “J” drain trap assembly was removed.

3. Remove the piece of soft tubing running from the in-line drain assembly to the header box and place a ½” vinyl cap over the drain tap in the in-line drain assembly.

4. Remove the gray tubing from the pressure tap on the header box. Remove the ¼” cap from the pressure tap on the right side of the header box and place it on the corresponding pressure tap on the opposite of the header box.

5. Place the gray tubing that was removed, to the corresponding pressure tap on the right side of the header box. (Refer to Figure

6. If ﬁ eld supplied parts are used, disconnect both soft tubes from the hard “J” tube drain trap after loosing 7/8” clamps. Shorten long side of the “J” trap by 8-1/2”.

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7. Feed the 10” piece of soft tubing through the round hole located in the right side of the cabinet wrapper Note: A downward slope must be maintained on the tube as it is routed through the furnace (when the furnace is in the horizontal position).

8. Assemble the 10” piece of soft tube to 5” tall end of the hard (J) tube to the end of the 10” soft tube located outside of the furnace. Secure the connection using one of the clamps that was removed, from the “J” trap. Secure the connection with the 7/8” hose clamp.

9. Reassemble the 30” piece of soft tubing removed from the factory installed “J” tube drain trap to the 2’ tall end of the modiﬁ ed “J” tube drain trap.

Note: Ensure the clamps in step 7 and 8 are securely tightened in order to avoid any condensate leakage. Note: PVC “T” drain assembly must be installed so that condensate does not get into the induced draft blower.( refer to Figure 2). Note: To avoid condensate freezing in the drain trap assembly and tubing, insulate around the drain trap assembly and all tubing located in unconditioned space.

Conversion of the *TE Upﬂ ow Furnace for a Horizontal Left Installation.

Refer to Figure 3.

1. Remove the hard “J” tube drain trap assembly.

2. If ﬁ eld supplied parts are used, disconnect both soft tubes from the hard “J” tube drain trap after loosing 7/8” clamps. Shorten long side of the “J” trap by 8-1/2”.

3. Feed the 10” piece of soft tubing through the round hole located in the left side of the cabinet wrapper. Note: A downward slope must be maintained on the tube as it is routed through the furnace (when the furnace is in the horizontal position).

4. Assemble the 5” tall end of the hard “J” tube to the end of the 10” soft tube located outside of the furnace. Secure the connection using one of the 7/8” hose clamps that were removed from the “J” trap.

5. Assemble the 30” piece of soft tubing that was removed from the “J” trap to the 2” tall end of the modiﬁ ed “J” drain trap. Secure the connection with the 7/8” hose clamp.

NOTE: To avoid condensate freezing in the drain trap assembly and tubing, insulate around the drain trap assembly and all tubing located in unconditioned space.

5/8" Vinyl Cap

1/4" Vinyl Cap

Drain Trap

1/2" Vinyl

Cap

Pressure Switch

Soft

Tubing

3" to 2"

Reducer

(Optional)

Grey

PVC Tee

PVC Reducer

Bushing

Soft Tubing

Looped to Provide

a Drain Trap

Figure 2. 90+ Upﬂ ow Converted for Horizontal Installation (Horizontal Right)

3" to 2"

Alternative

for

Horizontal

Vent

PVC Tee

Reducer

(Optional)

Drainage Port

is Downward

Pressure Switch

(Condensate)

Soft Tubing

Vinyl Cap

NOTE: When converting the

furnace, to horizontal left, ensure that the drainage port on the in-line drain assembly

Reducer Bushing

Soft Tubing

Looped to Provide

a Drain Trap

Pressure

Switch

Soft

Tubing

Grey Tub in g

1/4" Vinyl Cap

Drain Trap

is downward as shown in this ﬁ gure. If the in-line drain assembly is not rotated, then the furnace may not drain properly.

Figure 3. 90+ Upﬂ ow Converted for Horizontal Installation (Horizontal Left)

Page 8

CIRCULATING AIR SUPPLY

Plenums and air ducts must be installed in accordance with the Standard for the Installation of Air Conditioning and Ventilating Systems (NFPA No. 90A) or the Standard for the Installation of Warm Air Heating and Air Conditioning Systems (NFPA No. 90B).

If outside air is utilized as return air to the furnace for ventilation or to improve indoor air quality, the system must be designed so that the return air to the furnace is not less than 50°F (10°C) during heating operation. If a combination of indoor and outdoor air is used, the ducts and damper system must be designed so that the return air supply to the furnace is equal to the return air supply under normal, indoor return air applications.

When a cooling system is installed which uses the furnace blower to provide airﬂ ow over the indoor coil, the coil must be installed downstream (on the outlet side) or in parallel with the furnace.

If a cooling system is installed in parallel with the furnace, a damper must be installed to prevent chilled air from entering the furnace and condensing on the heat exchanger. If a manually operated damper is installed, it must be designed so that operation of the furnace is prevented when the damper is in the cooling position and operation of the cooling system is prevented when the damper is in the heating position.

Return Air

The return air ductwork may be connected to any or all of the following: left side return, right side return, or bottom return. Where maximum

airﬂ ow is 1800 CFM or more two openings must be used.

Determining Nominal AC System Capacity

In order to select the appropriate airﬂ ow for AC operation the nominal system capacity must be known. The nominal system capacity is

Upﬂ ow Models

Protective Screen

Figure 4. Protective Screen for

One Pipe Installations

WARNING:

Products of combustion must not be allowed to enter the return air ductwork or the circulating air supply. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death.

All return ductwork must be secured to the furnace with sheet metal screws. For installations in conﬁ ned spaces, all return ductwork must be adequately sealed and joints must be taped. When return air is provided through the bottom of the furnace, the joint between the furnace and the return air plenum must be sealed.

The ﬂ oor or platform on which the furnace is mounted must provide sound physical support of the furnace with no gaps, cracks, or sagging between the furnace and the ﬂ oor or platform.

Return air and circulating air ductwork must not be connected to any other heat producing device such as a ﬁ replace insert, stove, etc.

Page 9

ALWAYS the nominal capacity of the outdoor unit. In some cases the nominal system capacity is not the same as the nominal capacity of the indoor coil.

Selecting the AC Cooling Airﬂ ow

A/C cooling is referred to in the User’s manual of the IQ Drive Programmable thermostat.

Selecting the Heating Airﬂ ow

Furnace temperature rise depends on airﬂ ows rate. To select the air ﬂ ow, enter the programming screen on the IQ thermostat. Select the furnace input rate and then select the desired temperature rise (see Table 1).

NOTE: To set too high temperature rise of the furnace may result in air limit operation.

VENTING AND COMBUSTION AIR REQUIREMENTS

These condensing furnaces may be installed with outdoor combustion air piped directly to the furnace, or without such special piping. Codes refer to the former as “direct vent” or “two pipe” installation. Installation with air taken from around the furnace is sometimes referred to as “one pipe” installation - i.e. only the vent (exhaust) pipe is provided.

Provisions must be made for adequate supply of air for combustion and ventilation. For United States installations, the adequacy of air provisions can be determined by consulting the current version of the National Fuel Gas Code (ANSI Z223.1/NPFA-54). For Canadian installations, requirements are speciﬁ ed in the National Standard of Canada (CAN/CGA B149.1 & .2). Consult local codes for special requirements.

An important consideration in selecting one or two pipe installation is the quality of the combustion air. Indoor air is sometimes contaminated with various household chemicals which can cause severe corrosion in the furnace combustion system.

NOTE: If the furnace is operated without adequate air for combustion and ventilation, it may not perform properly. Furnace components may be strained by high temperature and could fail prematurely.

WARNING:

Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code and all applicable local codes to provide sufﬁ cient combustion air for the furnace.

Combustion Air Quality

The recommended source of combustion air is to use the outdoor air supply. However, the use of indoor air in most applications is acceptable except as follows:

1. If the furnace is installed in a conﬁ ned space it is recommended that the necessary combustion air come from the outdoors by way of attic, crawl space, air duct, or direct opening.

2. If outdoor combustion air is used, there must be no exposure to the installations or substances listed in Item 3 below.

3. The following types of installation may require Outdoor Air for combustion, due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundry rooms

• Furnaces installed in hobby or craft

rooms

• Furnaces installed near chemical storage

areas

Exposure to the following substances in

the combustion air supply may also require Outdoor Air for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemi-

cals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

Page 10

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

Air Requirements For One-Pipe Installation

When air for combustion is to be taken from around the furnace, a protective screen must be installed over the combustion air intake opening. This screen is provided with the furnace installation instructions and functions to prevent debris from entering the combustion system. It should be installed on the combustion air intake collar or inlet PVC. If furnace location is such that this opening might be unintentionally obstructed, a 3” PVC elbow should be installed on the collar, and the screen placed inside the inlet of the elbow. See Figure 4.

Installation In An Unconﬁ ned Space

Installation In A Conﬁ ned Space

A conﬁ ned space is one which does not meet the unconﬁ ned space volume requirements, and typically involves installation in a small room. All such installations must have speciﬁ c provisions for introduction of combustion and ventilation air. Codes require that two openings be provided for this - one with bottom edge within 12” of the ﬂ oor and one with top edge within 12” of the ceiling. The size and other criteria for these openings must be per the following sections.

Combustion air openings must not be restricted in any manner.

Furnaces installed in a conﬁ ned space which supply circulating air to areas outside of the space must draw return air from outside the space and must have return air ducts tightly sealed to the furnace.

CAUTION:

“Tight” buildings (with weather stripping and caulk to reduce inﬁ ltration), may require special provisions for introduction of outside air to ensure satisfactory combustion and venting, even though the furnace is located in an unconﬁ ned space.

An unconﬁ ned space is an area including all rooms not separated by doors with a volume greater than 50 cubic feet per 1,000 Btuh of the combined input rates of all appliances which draw combustion air from that space. For example, a space including a water heater rated at 45,000 Btuh and a furnace rated at 80,000 Btuh requires a volume of 6,250 cubic feet [50 x (45 + 80) = 6,250] to be considered unconﬁ ned. If the space has an 8 foot ceiling, the ﬂ oor area of the space must be 750 square feet (6,250 / 8 = 781). In general, a furnace installed in an unconﬁ ned space will not require outside air for combustion.

Air From Inside

Air for combustion and ventilation may be taken from inside the building through an interior wall if

the building is not “tight” and if the total volume of the furnace space and the space from which air is drawn meets the volume requirements for an unconﬁ ned space. In such cases, the

two openings in the wall must each have free area of at least one square inch per 1000 Btuh of total appliance input, but not less than 100 square inches of free area. See Figure 5. For example, if the combined input rate of all appliances is less than or equal to 100,000 Btuh, each opening must have a free area of at least 100 square inches. If the combined input rate of all appliances is 120,000 Btuh, each opening must have a free area of at least 120 square inches. (See Figure 5.)

Air Directly Through An Exterior Wall

If combustion air is provided directly through an exterior wall, the two openings must each have free area of at least one square inch per 4000 Btuh of total appliance input. (See Figure 6.)

WARNING:

Furnaces installed with combustion air drawn from a heated space which includes exhaust fans, ﬁ replaces, or other devices that may produce a negative pressure should be considered conﬁ ned space installations.

Outdoor Air Through Vertical Openings or Ducts

If combustion air is provided through vertical ducts or openings to attics or crawl spaces, the two openings must each have free area of at least one square inch per 4000 Btuh of total appliance input. Ducts must have cross-sectional areas at least as large as the free area of their respective openings to the furnace space. Attics or crawl spaces must communicate freely with the outdoors if they are the source of air

Page 11

for combustion and ventilation. (See Figures 7 and 8.)

Outdoor Air Through Horizontal Openings or Ducts

If combustion air is taken from outdoors through horizontal ducts, the openings must each have free area of at least one square inch per 2000 Btuh of total appliance input. Ducts must have cross-sectional area at least as large as the free area of their respective openings to the furnace space. (See Figure 9.)

CAUTION:

Do not supply combustion air from an attic space that is equipped with power ventilation or any other device that may produce a negative pressure.

VENTING REQUIREMENTS

This section speciﬁ es installation requirements for vent and “2-pipe” combustion air piping. For “one pipe” installations, install vent piping per this section and provide air for combustion and ventilation per the previous section. The capacity

table provided in this section applies to the total of vent and combustion air piping for either type of installation.

These condensing furnaces are classiﬁ ed as “Category IV” appliances, which require special venting materials and installation procedures. Category IV appliances operate with positive vent pressure and therefore require vent systems which are thoroughly sealed. They also produce combustion condensate, which is slightly acidic and can cause severe corrosion of ordinary venting materials. Furnace operation can be adversely affected by restrictive vent and combustion air piping. Therefore, vent and combustion air piping lengths must conform completely to the requirements of Table 3.

The furnace must be vented to the outdoors. It must not be vented in common with any other appliance, even if that appliance is of the condensing type. Common venting can result in severe corrosion of other appliances or their venting and can allow combustion gases to escape through such appliances or vents. Do not vent the furnace to a ﬁ replace chimney or building chase.

APPLICATION

PVC,CPVC or ABS

SCH. 40 Pipe Size

Models *TE 060 65 200 30 30 40 40 110 110

Models *TE 080 45 200 30 30 40 40 110 110

Models *TE 100 40 200 25 25 40 40 110 110

Models *TE 120 40 200 20 20 40 40 110 110

**NOTES

1. Subtract 2.5 ft. for each additional 2” long radius elbow, 5 ft. for each additional 2” short radius elbow, 3.5’ for each additional 3” long radius elbow, and 7’ for each additional 3” short radius elbow.

2. Two 45 degree elbows are equivalent to one 90 degree elbow.

3. Do not include termination elbows in calculation of vent length

4. This table is applicable for elevations from sea level to 2000 ft. For higher elevations decrease vent pipe lengths by 8% per 1000 ft. of altitude.

5. Only the above pipe materials are approved for use with these condensing furnaces.

SINGLE PIPE LENGTH (ft.)

with 1 long radius elbow**

Outlet Outlet Inlet/Outlet Inlet/Outlet Inlet/Outlet

2” 3” 2” 2” 3” 2” 3” 3”

DIRECT VENT, DUAL PIPE LENGTH (ft.)

with 1 long radius elbow on each pipe**

Table 3. Vent Table

Page 12

Vent or Chimney

Each opening must be at least 100 sq. in. or 1 sq. in. per 1000 Btuh of total input rating, whichever is greater. See minimum area per table.

12" Max.

Each opening to outside must be at least 1 sq. in. per 4000 Btuh of total input rating.

12"

Max

Vent or Chimney

Furnace

12" Max.

Water Heater

Total Input

Rating (Btuh)

40,000 60,000 80,000 100,000 120,000 140,000 160,000

Minimum

Free Area

(Each Opening)

100 sq. in. 100 sq. in. 100 sq. in. 100 sq. in. 120 sq. in. 140 sq. in. 160 sq. in.

Round Duct

Diameter

12" 12" 12" 12" 13" 14" 15"

Figure 5. Equipment in a

Conﬁ ned Space with all

Combustion Air drawn from Inside

Ventilation Louvers at each end of attic

Vent or Chimney

Attic Insulation

Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating.

Ducts must extend above attic insulation.

Furnace

12" Max

Water Heater

Minimum

Total Input

Rating (Btuh)

40,000 60,000 80,000 100,000 120,000 140,000 160,000

Free Area

(Each Opening)

10 sq. in. 15 sq. in. 20 sq. in. 25 sq. in. 30 sq. in. 35 sq. in. 40 sq. in.

Round Duct

Diameter

4" 5" 5" 6" 6" 7" 8"

Figure 6. Equipment in a Conﬁ ned Space

with all Combustion Air drawn from Out-

doors through Exterior Wall

Vent or Chimney

Air Duct must be at least 1 sq. in.

Furnace

Water Heater

per 4,000 Btuh of total input rating.

12" Max

Minimum

Total Input

Rating (Btuh)

40,000 60,000 80,000 100,000 120,000 140,000 160,000

Free Area

(Each Opening)

10 sq. in. 15 sq. in. 20 sq. in. 25 sq. in. 30 sq. in. 35 sq. in. 40 sq. in.

Round Duct

Diameter

4" 5" 5" 6" 6" 7" 8"

Figure 7. Equipment in a Conﬁ ned Space

with all Combustion Air drawn from

Outdoors through Vertical Ducts – from

Ventilated Attic

Ventilation Louvers (each end of attic)

---------

Furnace

Alternate

Air Inlet

Outlet Air

Water Heater

Inlet Air

---------

Ventilation Louvers For Unheated Crawl Space

NOTE: Air openings shall each have a free area of not less than one square inch per 4,000 Btuh of the total input rating of all equipment in the enclosure.

---------

Figure 8. Equipment in a Conﬁ ned Space

with all Combustion Air drawn from Out-

doors through Ventilated Crawl Space and

Ventilated Attic

Page 13

Vent or Chimney

Each opening to outside must be at least 1 sq. in. per 2000 Btuh of total input rating.

12" Max

Total Input

Rating (Btu/hr)

40,000 60,000 80,000 100,000 120,000 140,000 160,000

12" Max

Air Duct

Furnace

Minimum

Free Area

(Each Opening)

20 sq. in. 30 sq. in. 40 sq. in. 50 sq. in. 60 sq. in. 70 sq. in. 80 sq. in.

Water Heater

Round Duct

Diameter

5" 6" 7" 8" 9" 10" 10"

Figure 9. Equipment in a Conﬁ ned Space

with all Combustion Air Drawn from the

Outside through Horizontal Ducts

WARNING:

FURNACE MUST NOT BE COMMON VENTED WITH OTHER APPLIANCES.

3. So far as is practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.

4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously.

5. Turn on clothes dryers and any other appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan.

6. Close ﬁ replace dampers.

7. Test for spillage from draft hood equipped appliance at the draft hood relief opening after 5 minutes of main burner operation. Use the ﬂ ame of a match or candle.

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas

Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Codes.

9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, ﬁ replace dampers and any other gas burning appliance to their previous conditions of use.

WARNING:

CARBON MONOXIDE POISONING

HAZARD

1. Seal any unused openings in the venting system

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1 or the CAN/CGA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deﬁ ciencies which could cause an unsafe condition.

Vent Pipe Material

Vent and combustion air pipe and ﬁ ttings must be one of the following materials and must conform to the indicated ANSI/ASTM standards:

Material Standard

Schedule 40 PVC D1785 PVC-DWV D2665 SDR-21* D2241 & SDR-26* ABS-DWV D2661 Schedule 40 ABS F628 Foam/Cellular Core PVC F891

Page 14

Upﬂ ow Furnaces

Exhaust

Inlet

5/8"

Supports at Minimum of 5 ft. Intervals

Combustion Offset with

Exhaust Pipe for Adequate Dimensional Clearance

PVC or ABS Pipe

Straight Neoprene Coupling with 2 Hose Clamps* (Optional - Not Shown)

Figure 10. Horizontal Venting

* These neoprene couplings are ﬁ eld-supplied and can be used if the installation requires breakable connec-

tions in the piping. Note that a maximum of two couplings per pipe are allowed.

See Vent Table 6

Straps or Other Suitable

Upward Pitch - 1/4" per Foot

Outlet Exhaust Vent

First Support Placed as Close to Furnace Connection as Possible

Exhaust Vent

Seal/Caulk around Pipe at Building

90° Elbow

12" Min.

Wall

Normal Snow Level

Upﬂ ow Furnaces

Combustion

Air Pipe

Furnace Front

Support System with

first support as close

to furnace as Possible

Exhaust

Vent

Straight Neoprene Couplings with 2 Hose Clamps* (Optional - Not Shown)

Cabinet

Support System on

Vertical Rise Below Joints

Upward Pitch 1/4" per Foot

Figure 11. Vertical Venting

* These couplings are ﬁ eld-supplied and can be used if the installation requires breakable connections in the

piping. Note that a maximum of two couplings per pipe are allowed.

Upﬂ ow Furnaces

Combustion Air Inlet Pipe Collar Diameter 3" for coupling

Furnace Top

2" PVC

Exhaust Vent

Use 2" to 3" reducer

Figure 12. Furnace Pipe Adaptions

Page 15

Note: In Canada, vent materials must be certiﬁ ed to the Standard for Type BH Gas Venting System, ULC S636. Any certiﬁ ed ULC S636 material must not be interchanged with unlisted or non certiﬁ ed pipes and/or ﬁ ttings. The plastic components, speciﬁ ed primers and glues of the certiﬁ ed vent system must not be intermixed with any other manufacturer’s vent systems or parts.

Cement and primer must conform to ATSM Standard D2564 for PVC and Standard D2235 for ABS. When joining PVC piping to ABS, use PVC solvent cement. (See procedure speciﬁ ed in ASTM Standard D3138.)

Vent Pipe Length and Diameter

In order for the furnace to operate properly, the combustion air and vent piping must not be excessively restrictive. To ensure this use Table 3, which indicates the maximum allowable piping length for a furnace of speciﬁ ed input rate, when installed with piping of selected diameter and number of elbows. This table applies to the length and number of elbows for each pipe. To use the table, the furnace input rate, the centerline length and the number of elbows on each pipe must be known. Choose the diameter for which the tabulated length is equal to or greater than required.

Proper use of the table is illustrated by the following example:

Example:

A 120,000 Btu/h furnace is to be installed in a “one-pipe” system with 40 feet of vent piping. There are a total of four long radius 90-degree elbows used in the vent, including the one exterior to the building.

Solution:

For this particular installation, the equivalent vent length must be calculated. This equivalent vent length will then be compared to the maximum allowable vent length given in Table 3. Then, the diameter of the piping can be chosen for which the equivalent vent length is less than the maximum allowable vent length. Returning to our example, we consult Table 3 and determine that for a 120,000 Btu/h furnace the maximum vent length for 3” diameter piping is 110 feet. Note that the maximum vent length given in Table 3 includes one long radius elbow. Therefore, for our example, we have three additional long radius elbows for which we must add to our piping. Each long radius elbow is equivalent to 2.5 feet, so we

must add 7.5 feet to our vent length. Therefore, the equivalent vent length for our installation is

47.5 feet. We compare this with the maximum vent length for 3” diameter piping. Our equivalent vent length is less than the maximum allowable vent length, so for our “one-pipe” installation we can use 3” diameter piping.

Condensing furnace combustion products have very little buoyancy, so Table 3 is to be used without consideration of any vertical rise in the piping.

Vent Pipe Installation

Pipe Routing and Support

Route piping as directly as possible between the furnace and the outdoors and remember that routing affects pipe size requirements per the preceding section. If a two pipe system is used, locate the combustion air intake and the vent exhaust in the same atmospheric pressure zone

- i.e. both must exit the building though the same portion of exterior wall or roof. Vent piping must be sloped upwards not less than 1/4” per foot in the direction from the furnace to the terminal. This is to ensure that any condensate ﬂ ows back to the furnace (where it can be disposed of through the condensate disposal system).

The quality of outdoor air must also be considered. Be sure that the combustion air intake is not located near a source of solvent fumes or other chemicals which can cause corrosion of the furnace combustion system.

CAUTION:

Combustion air must not be drawn from a corrosive atmosphere.

Piping must be mechanically supported so that its weight does not bear on the furnace. Supports must be at intervals no greater than ﬁ ve feet, and at smaller intervals if necessary to ensure that there are no sagging sections to trap water. (See Figures 10 and 11.) It is recommended to install couplings along the vent pipe, on either side of the exterior wall. These couplings may be required by local code.

Figure 12 illustrates vent and combustion air pipe sizes exiting the furnace. Transition to the correct pipe size (i.e. from 2” to 3” diameter) must be done close to the furnace so that the full length of pipe is of proper size.

Page 16

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

A =

Clearance above grade, veranda, porch,

Canadian Installations

US Installations

12 inches (30 cm) 12 inches (30 cm)

deck, or balcony

B =

Clearance to window or door that may be opened

C =

Clearance to permanently closed window

D =

Vertical clearance to ventilated sofﬁ t located above the terminal within a horizontal distance of 2 feet (61 cm) from the center

6 inches (15 cm) for appliances 10,000 Btuh (3 kW), 12 inches (30 cm) for appliances > 10,000 Btuh (3 kW) and 100,00 Btuh (30 kW),

6 inches (15 cm) for appliances 10,000 Btuh (3 kW), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kW) and 50,000 Btuh (15 kW),

line of the terminal

E =

Clearance to unventilated sofﬁ t

F =

Clearance to outside corner

G =

Clearance to inside corner

H =

Clearance to each side of center line extended above meter/regulator assembly

I =

Clearance to service regulator vent outlet 3 feet (1.83 m)

J =

Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance

3 feet (91 cm) within a height 15 feet above the meter/regulator assembly

6 inches (15 cm) for appliances 10,000 Btuh (3 kW), 12 inches (30 cm) for appliances > 10,000 Btuh (3 kW) and 100,00 Btuh (30 kW),

K =

Clearance to a mechanical air supply inlet 6 feet (1.83 m) 3 feet (91 cm) above if within 10 feet

6 inches (15 cm) for appliances 10,000 Btuh (3 kW), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kW) and 50,000 Btuh (15 kW),

(3 m) horizontally

L =

Clearance above paved sidewalk or paved driveway located on public property

M =

Clearance under veranda, porch deck, or balcony

7 feet (2.13 m) †

12 inches (30 cm) ‡

In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code

In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both

dwellings. ‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the ﬂ oor. * For clearances not speciﬁ ed in ANSI Z223.1 / NFPA 54 or CSA B149.1, the following statement shall be included:

“Clearance in accordance with local installation codes, and the requirements of the gas supplier

Figure 13. Vent Termination Clearances for Direct Vent Furnaces

and the manufacturer’s installation instructions.”

Page 17

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

A =

Clearance above grade, veranda, porch,

Canadian Installations

US Installations

12 inches (30 cm) 12 inches (30 cm)

deck, or balcony

B =

Clearance to window or door that may be opened

6 inches (15 cm) for appliances 10,000 Btuh (3 kW), 12 inches (30 cm) for appliances > 10,000 Btuh (3 kW)

4 feet (1.2 m) below or to side of opening; 1 foot (300 mm) above

opening and 100,00 Btuh (30 kW), 36 inches (91 cm) for appliances >100,00 Btuh (30 kW)

C =

Clearance to permanently closed window

D =

Vertical clearance to ventilated sofﬁ t located above the terminal within a horizontal distance of 2 feet (61 cm) from

the center line of the terminal

E =

Clearance to unventilated sofﬁ t

F =

Clearance to outside corner

G =

Clearance to inside corner

H =

Clearance to each side of center line extended above meter/regulator assembly

I =

Clearance to service regulator vent outlet 3 feet (1.83 m)

J =

Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance

3 feet (91 cm) within a height 15 feet above the meter/regulator assembly

6 inches (15 cm) for appliances 10,000 Btuh (3 kW), 12 inches (30 cm) for appliances > 10,000 Btuh (3 kW) and

4 feet (1.2 m) below or to side of

opening; 1 foot (300 mm) above

opening 100,00 Btuh (30 kW), 36 inches (91 cm) for appliances >100,00 Btuh (30 kW)

K =

Clearance to a mechanical air supply inlet 6 feet (1.83 m) 3 feet (91 cm) above if within 10 feet

(3 m) horizontally

L =

Clearance above paved sidewalk or

7 feet (2.13 m) † 7 feet (2.13 m)

paved driveway located on public property

M =

Clearance under veranda, porch deck, or balcony

In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code

In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both

“Clearance in accordance with local installation codes, and the requirements of the gas supplier

Figure 14. Vent Termination Clearances for other than Direct Vent Furnaces

12 inches (30 cm) ‡

and the manufacturer’s installation instructions.”

Page 18

Straight neoprene couplings are supplied with the downﬂ ow furnaces only. These couplings are to be installed in the combustion air inlet (if present) and exhaust vent piping at the furnace as shown in Figure 11. For an upﬂ ow furnace installation, if breakable connections are required in the combustion air inlet (if present) and exhaust vent piping, then straight neoprene couplings for 3” piping with hose clamps can be used. These couplings can be ordered through your local furnace distributor.

To install a coupling, slide the rubber coupling over the end of the pipe that is attached to the furnace and secure it with one of the hose clamps. Then slide the other end of the rubber coupling onto the other pipe from the vent and secure the coupling with the second hose clamp. For the upﬂ ow models, the combustion air pipe can be attached to the furnace. Ensure that the connection is tight and leak free.

These condensing furnaces have been certiﬁ ed for installation with zero clearance between vent piping and combustible surfaces. However, it is good practice to allow space for convenience in installation and service.

Location of Outdoor Terminations

Horizontal Venting

Vent and combustion air intake terminations must be as shown in Figures13 and 14. Vent termination clearances shall be consistent with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the CSA B149.1, Natural Gas & Propane Installation code.

All minimum clearances speciﬁ ed must be maintained to protect building materials from degradation by ﬂ ue gases.

Vent and combustion air intake terminations must be located to ensure proper furnace operation and to conform to applicable codes. Figures 13 and 14 illustrate necessary distances from the vent termination to windows and building air intakes.

In Canada, the Canadian Fuel Gas Code takes precedence over these instructions. Speciﬁ cally, all minimum distance requirements with respect to termination of the vent piping listed below (items 1 through 8).

The following list is a summary of vent terminal location requirements:

1. The termination must be 12 inches above snow level or grade level whichever is higher. See Figure 15 for alternate method to achieve 12” above snow level.

2. The minimum distance for a (1-pipe installation) from any door, (openable) window, or gravity air inlet is 4 ft. below, 4 ft. horizontally, or 1 ft. above.

3. The minimum distance for a direct vent (2pipe installation) from any door, (openable) window, or air gravity inlet is 1 ft. below, 1 ft. horizontally, or 1 ft. above.

4. For one-pipe installations the recommended minimum distance from an inside corner formed by two exterior walls is 6 feet, but is not required.

5. The vent termination for a 1-pipe installation shall be a minimum of 3 ft. above any forced air inlet within 10 ft.

6. The vent termination shall be located at least 4 ft. horizontally from any electric meter, gas meter, regulator and any relief equipment. These distances apply ONLY to U.S. installations. In Canada, the Canadian Fuel Gas Code takes precedence.

7. Avoid areas where condensate drainage may cause problems by dropping on planters or patios, etc. Also ensure that exhaust gases will not impinge on windows or building surfaces, which may be compromised or damaged by condensation. Do not install the vent terminal such that exhaust is directed into window wells, stairwells, under decks or into alcoves or similar recessed areas, and do not terminate above any public walkways.

8. Select the point of wall penetration where the minimum 1/4 inch per foot of slope up can be maintained.

Vent Configuration to Provide 12" Minimum height above Snow Level.

Outside Wall

12" Min.

19" Max.

Support

1/2" Armaflex Insulation or Equivalent (if required)

12" Above Normally Expected Snow Level

Figure 15. Alternate Horizontal Vent Installation

Page 19

CAUTION:

For optimum performance, vent furnace through wall which experiences the least exposure to winter winds.

WARNING:

Ensure that the combustion air vent and the exhaust vent are conﬁ gured as shown in Figure 16. Improper vent termination can cause recirculation of the ﬂ ue gases. This may result in furnace vibration. In severe cases, the furnace will cycle due to the intermittent contact between the ﬂ ame and the ﬂ ame sensor. If you note oscillations occurring, check the vent conﬁ guration. Make sure that the exhaust vent does not have a 90 degree termination.

For Canadian installations please refer to the Canadian Installation Code (CAN/CGA-B149.1 or 2) and/or local codes. The kit consists of two face plates and an insulating gasket to seal the exterior surface. A hole sized closely to the pipe diameter must ﬁ rst be cut through the wall. A short length of pipe is then cut such that it can penetrate the wall and be held in place by closely ﬁ tting standard couplings. The face plates are retained on both sides of the wall by the couplings, and the gasket is retained against the wall by the outer face plate. Face plates must be fastened to the wall and the outside one must be ﬂ ashed as appropriate to prevent entry of water.

When the above kits are not used the following steps are required:

1. Check the hole size cut through the exterior wall. Insure that the hole diameter is less than the diameter of the couplings to be used.

2. Extend the vent pipe through the wall approximately 1” and seal the area between the wall and pipe.

3. If required by local code, apply couplings to the vent pipe on the interior and exterior sides of the wall to insure the pipe can not be pushed or pulled through the wall.

4. Insure the combustion air inlet pipe (for a 2 pipe installation) has a 90 degree termination elbow as shown in Figures 16 and 17.

Note: A combustion air intake must be provided with an elbow opening downward. The screen provided with the furnace can be installed in the elbow to prevent entry of debris or creatures.

When the vent pipe must exit an exterior wall close to the grade or expected snow level, a riser should be provided as shown in Figures 15 and 16.

Table 3 describes the maximum length of ﬂ ue pipe that can travel through an unconditioned space or an exterior space. The total vent length must not exceed the lengths noted on Table 8.

Vertical Venting Figure 17 shows the proper installation and clearances for vertical vent termination. The roof penetration must be properly ﬂ ashed and waterproofed with a plumbing roof boot or equivalent ﬂ ashing. Termination spacing requirements from the roof and from each other must be per Figure 17.

Vent and combustion air piping may be installed in an existing chimney which is not in use provided that:

a. Both the exhaust vent and air intake run

the length of the chimney.

b. The top of the chimney is sealed and

weatherproofed.

c. The termination clearances shown in

Figure 17 are maintained.

d. No other gas fired or fuel burning

appliances are vented through the chimney.

Vent Freezing Protection

When the vent pipe is exposed to temperatures below freezing, i.e., when it passes through unheated spaces, chimneys, etc., the pipe must be insulated with 1/2 inch thick sponge rubber insulation, Armaﬂ ex-type insulation or equivalent. Insulating pipe is important to avoid condensate icing.

For extremely cold climates or for conditions of short furnace cycles (i.e. set back thermostat conditions) the last three feet of vent pipe can be reduced one nominal pipe size provided that the total vent length is at least 15 feet in length and

Page 20

the vent is sized in accordance with the venting requirements (Table 4) before this reduction is applied. (Example: 3” to 2-1/2”) Smaller vent pipes are less susceptible to freezing, but must not be excessively restrictive.

3. Re-tighten the clamp. MAKE SURE CLAMP IS TIGHT TO AVOID LEAKAGE OF CONDENSATE.

4. Route the tubing out of the hole located 8 inches up from the bottom furnace.

Concentric Vent Termination

A concentric vent termination is approved for use with these furnaces. The kit part number is

904176. For proper installation of the concentric vent termination, follow the installation instructions provided with that kit.

DRAINAGE OF CONDENSATE FROM FURNACE

The condensate drainage system is internal to the furnace. It is not recommended to connect additional traps to the exterior of the furnace. Doing so will have adverse effects on the operation of the furnace. The drain may exit either the right or left side of the furnace cabinet.

The condensate drain can be routed to a ﬂ ow drain or to a condensate pump. Ensure that the drain maintains a downward slope from the unit to the drain. Refer to Figure 18 for more details.

For a right side drain simply extend the tubing out of the hole in the cabinet, see Figure 18. For a left side drain follow the steps below:

1. Loosen the clamp on the soft exit tube (see Figure 18.)

2. Rotate the soft exit tube (counter clockwise, 180° upﬂ ow models; clockwise 90° downﬂ ow models.)

The condensate should drain from the plastic collector box (location A in Figure 18) as droplets or a small stream. If you notice the furnace has operated for more than 5 minutes without draining or the red status light on the control board is pulsing a 2-blink code follow the steps below.

1. Remove the collector box soft tube at location A in Figure 18 and insure the exit from the collector box is clear of any debris or obstructions.

2. Replace this tube and insure the ﬁ t to the header spout is air tight. Air will be drawn into the header if this connection is not tight.

3. Check other tube connections along the drain system. Insure that all are air tight.

NOTE: Industry research studies indicate that when condensate is routed to an active drain, household detergents, etc., buffer its acidity. If the drain is not actively used or if codes require, obtain a neutralizer kit NORDYNE part no. 902373 (usually contains limestone). Proper drains and connections to the condensate tubing are required as NORDYNE cannot be held responsible for water leakage which occurs due to loose hose connections or improperly sealed drain line pipes.

Exhaust Vent

Mounting Kit

Faceplate Secured

to Wall with Screws

Combustion

Air Inlet

Exhaust Vent

Option C

Figure 16. Exhaust and Combustion Air Pipe Clearances

Option B

7" Min.

18" Min.

36" Max.

18" Min. 36" Max.

18" min.

36" max.

12" Min. to

Normal Snow Level

Inlet

Exhaust Vent

Option A

8" Min.

Grade Level or Normal Snow

Exhaust

Page 21

Exhaust

Elbow

Combustion

Air

Intake

Vent 1"

18" Min. 36" Max.

Exhaust

Plumbing Vent Roof Boot (Typ. Both Pipes)

A= 12” Above Roof or Snow Accumulation

Level

Figure 17. Vertical Vent Termination

GAS SUPPLY AND PIPING

This furnace is equipped for either left or right side gas entry. Typical gas service hook-ups are shown in Figure 19. When making the gas connection provide clearance between the gas supply line and the entry hole in the furnace casing to avoid unwanted noise and/or damage to the furnace.

All gas piping must be installed in compliance with local codes and utility regulations. Some local regulations require the installation of a manual main shut-off valve and ground joint union external to the furnace. The shut-off valve should be readily accessible for service and/or emergency use. Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut-off. In the absence of local codes the gas line installation must comply with the latest edition of

the National Fuel Gas Code (ANSI Z223.1) or (CAN/CGA B149) installation codes.

An 1/8” NPT plugged tap must be installed in the gas line to the unit for use when measuring the gas supply pressure. The plug should be readily accessible for service use. A drip leg should be installed in the vertical pipe run to the unit. Table 6 lists gas ﬂ ow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line.

NOTE: Gas piping must not be run in or through air ducts, chimneys, gas vents, elevator shafts, etc.

Compounds used on threaded joints of gas piping must be resistant to the actions of liqueﬁ ed petroleum gases.

The main manual gas valve and main power disconnect to the furnace must be properly labeled by the installer in case emergency shutdown is required.

CAUTION:

Do not use matches, lighters, candles, or other sources of open ﬂ ame to check for gas leaks.

Leak Check

After the gas piping to the furnace is complete, all connections must be tested for gas leaks.

Upﬂ ow Models

Left Side

Figure 18. Furnace with Condensate Drain Trap Assembly

Drain

"HARD" J Drain Tube

Collector Box

Rotate counter clockwise (Step 2)

Clamp (Loosen For Step 1) (Retighten for Step 3)

Route to floor drain. ...OR Route to condensate pump. Keep downward slope.

Page 22

Unconditioned and Exterior Spaces

Winter Design

Temperature (°F)

20 70 90

04590

-20 35 80

‡ = Insulation thickness greater than 3/8 inch, based on an R value of 3.5 (ft*°F*hr)/(BTU*in)

WARNING:

Table 4. Vent Protection

Without Insulation

FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Never test for gas leaks with an open ﬂ ame. Use a commercially available soap solution made speciﬁ cally for the detection of leaks to check all connections. A ﬁ re or explosion may result causing property damage, personal injury or loss of life.

IMPORTANT NOTE: When pressure testing gas supply lines at pressures greater than 1/2 psig (14 in. water column), the furnace must be disconnected from the gas supply piping system to prevent damage to the gas control valve. If the test pressure is less than or equal to 1/2 psig (14 in. water column), the furnace must be isolated from the gas supply line by closing the manual shut-off valve.

WARNING:

This furnace was equipped at the factory for use with natural gas only. A special kit, supplied by the manufacturer, is required to convert the furnace to operate on LP/propane gas. Failure to use the proper conversion kit can cause ﬁ re, explosion, property damage, carbon monoxide poisoning, personal injury, or death.

Maximum Flue Pipe Length in

With Insulation

(feet)

(feet) ‡

Upﬂ ow Models

Burner Viewport

Denotes fieldprovided and installed components.

Shut-Off Valve

with 1/8" NPT

Plugged Tap

Some Utilities

Require Shut-

Off Valve to

be 4 to 5 feet

Above Floor

Dripleg

Roll-Out Limit

Burner Assembly

Ground Joint Union

Automatic Gas Valve

(with manual shut-off)

Figure 19. Typical Gas

Service Connection

MANIFOLD PRESSURE ADJUSTMENT

Manifold pressures for low and high stages are independently adjustable. Adjustment tap locations on the valve are shown in Figure 20. Manifold pressure would be adjusted below procedure:

- Turn off gas shut off valve outside furnace.

- Install manometer on the gas valve at the outlet pressure tap.

- Turn on the shut off. Run furnace at high ﬁ re and set manifold pressure. Also set manifold pressure while running at low ﬁ re (refer to Tables 6 and 7.)

- Ensure plug is tight after removing manometer.

Conversion

Conversion of this furnace to use LP/propane gas must be made by qualiﬁ ed service personnel, using only approved parts.

Page 23

CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR) FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60)

NOMINAL

BLACK IRON

PIPE DIAMETER

(in.)

1/2 130 90 75 65 55 50 45 40

3/4 280 190 150 130 115 105 95 90

1 520 350 285 245 215 195 180 170

1 1/4 1050 730 590 500 440 400 370 350

1 1/2 1600 1100 890 760 670 610 560 530

10 20 30 40 50 60 70 80

LENGTH OF PIPE RUN

The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas ﬂ ow required by the furnace. To determine the cubic feet per hour of gas ﬂ ow required by the furnace, divide the input rate

of the furnace by the heating value of the gas:

Cubic Feet Per Hour Required = Input To Furnace (Btu/hr) Heating Value of Gas (Btu/Cu. Ft.)

Table 5. Capacity of Black Iron Gas Pipe (cu. ft. per hour)

for Natural Gas (speciﬁ c gravity = .60)

For a Natural Gas Sea Level Heating Value of 800 to 899 Btu/cu.ft.

Elevation (feet above sea level)

Manifold Pressure Setting (in

WC)

zero to

1999

Full Input 3.5 3.5 3.5 3.5 3.0

Low Input 1.7 1.7 1.7 1.7 1.6

2000 to

4999

5000 to

5999

6000 to

7999

8000 to

10000

For a Natural Gas Sea Level Heating Value of 900 to 999 Btu/cu.ft.

Elevation (feet above sea level)

Manifold Pressure Setting (in

WC)

zero to

1999

Full Input 3.5 3.5 3.5 3.2 2.8

Low Input 1.7 1.7 1.7 1.6 1.5

2000 to

4999

5000 to

5999

6000 to

7999

For a Natural Gas Sea Level Heating Value of 1,000 to 1,100 Btu/cu.ft.

Elevation (feet above sea level)

Manifold Pressure Setting (in

WC)

zero to

1999

Full Input 3.5 3.5 3.0 2.8 2.5

Low Input 1.7 1.7 1.5 1.4 1.3

2000 to

4999

5000 to

5999

6000 to

7999

Table 6. Manifold Pressure (in WC) for Natural Gas at Various Altitudes

For a LP Gas Sea Level Heating Value of 2,500 Btu/hr.

Elevation (feet above sea level)

Manifold Pressure Setting (in

WC)

zero to

1999

Full Input 10 8.5 10 9 8.5

Low Input 5.5 5.5 6.5 6.5 6.5

2000 to

4999

5000 to

5999

6000 to

7999

8000 to

10000

8000 to

10000

8000 to

10000

Table 7. Manifold Pressure (in WC) for LP/Propane Gas at Various Altitudes

Page 24

IMPORTANT NOTE: When converting a low NOx furnace from Natural Gas to LP/Propane Gas, it is necessary to remove the NOx bafﬂ es from the furnace.

HIGH ALTITUDE CONVERSION High Altitude Application

Conversion of this furnace to replace the pressure switch or to utilize LP/propane gas must be made by qualiﬁ ed service personnel, using factory authorized or approved parts. High altitude applications with this furnace can be ﬁ eld performed by a simple adjustment of manifold pressure, and if necessary changing the oriﬁ ces and the vent pressure switch. The changes required depend on the installation altitude and the heating value of the gas. The gas heating value based on sea level can be obtained from your local gas utility. The heating value of gas at high altitude is always lower than the sea level heating value. The heating values used in Tables 10 and 11 are based on sea level values.

HIGH STAGE ADJUSTMENT UNDER VENT CAP

2-STAGE OPERATOR

INLET PRESSURE TAP 1/8 NPT

(Honeywell shown)

(4) QUICK DISCONNECT TERMINALS

1ST STAGE REGULATOR COVER REGULATOR ADJUST BENEATH THIS SCREW

VENT (.330 DIA. +DFT. POST) ACCEPTS 5/16” HOSE CONNECTION

VENT FITTING FOR 90 PLUS EFFICIENT APPLIANCES

LOW STAGE ADJUSTMENT UNDER VENT CAP

OUTLET PRESSURE TAP 1/8 NPT

INLET PRESSURE POST SET SCREW: 3/32” HEX HEAD (.339 DIA. +DFT.) ACCEPTS 5/18” HOSE CONNECTION

CONTROL LABEL

Pressure Switch Conversion for High Altitude Applications

These units are factory equipped to operate between zero and 8000 feet above sea level. For higher altitude applications, you may need to replace the vent pressure switch in addition to the main gas burner oriﬁ ces.

Natural Gas High Altitude Conversion

All factory shipped furnaces are ready to operate between zero and 4999 ft. above sea level. For higher altitudes (between 5000 and 10,000 ft. above sea level), conversion can be achieved simply by adjusting the furnace manifold pressure as shown in Tables 6 and 7.

LP/Propane Gas Sea Level and High Altitude Conversion

Conversion to LP/propane gas can be accomplished by ﬁ rst replacing the natural gas oriﬁ ces with the appropriate LP/propane oriﬁ ces shown in Table 8 or 9 Note: for installations between zero and 5000 ft. above sea level, refer to Table 8. For installations above 5000 ft. above sea level, refer to Table 9. After changing the oriﬁ ces, use Tables 7 and 9 to determine the appropriate manifold pressure for your installation.

2ND STAGE REGULATOR COVER REGULATOR ADJUST BENEATH THIS SCREW

OUTLET PRESSURE POST SET SCREW: 3/32” HEX HEAD (.339 DIA. +DFT.) ACCEPTS 5/18” HOSE CONNECTION

(White Rodgers shown)

Figure 20. Gas Valve

altitude is detailed in the installation instructions provided with the conversion kit. Approved conversion kits are listed below.

United States LP/Propane Gas Sea Level and High Altitude Conversion Kit - P/N 904404

This kit is for LP/propane conversion in the United States at altitudes between zero and 10,000 ft. above sea level. Follow the installation instructions supplied with the kit for proper installation.

Canadian LP/Propane Gas Sea Level and High Altitude Conversion Kit - P/N 904405

This kit is for LP/propane conversions in Canada at altitudes between zero and 4500 ft. above sea level. Follow the installation instructions supplied with the kit for proper installation.

Conversion to LP/propane, sea level, and high

Page 25

Furnace High Fire Rating

Plate Input (Btu/h)

60,000 49 56

80,000 45 55 100,000 45 55 120,000 45 55

Oriﬁ ce Drill Size

Nat. LP

Furnace High Fire Rating

Plate Input (Btu/h)

60,000 49 57

80,000 45 56 100,000 45 56 120,000 46 56

Oriﬁ ce Drill Size

Nat. LP

Table 8. Natural and LP Gas Oriﬁ ce Sizes

for Elevations between

zero and 4999 ft. Above Sea Level

CAUTION:

To avoid electric shock, personal injury, or death, turn off the power at the disconnect or the main service panel before making any electrical connections.

ELECTRICAL WIRING

Electrical connections must be made in accordance with all applicable local codes and ordinances, and with the current revision of the National Electric Code (ANSI/NFPA 70).

For Canadian installations electrical connections and grounding must be done in accordance with the current Canadian Electrical Code (CSA C22.1 Part 1) and/or local codes. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wire having a minimum temperature rating of 105°C. Refer to the furnace nameplate and Table 10 for electrical requirements.

Line Voltage Wiring

The line voltage (115 volt) to the furnace must be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace. See Table 10. An electrical switch should be readily accessible from and within sight of the furnace. (See the Wiring Diagram label in the furnace and Figure 21.)

Table 9. Natural and LP gas Oriﬁ ce Sizes

for Elevations between 5000 and 10,000 ft.

Above Sea Level

NOTE: Proper line voltage polarity must be maintained in order for the control system to operate correctly. Verify that the incoming neutral line is connected to the white wire and the incoming “hot” line is connected to the black wire in the junction box. These furnaces will not operate unless polarity and ground are properly connected. See Figure 21.

CAUTION:

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

NOTE: The following procedure describes

how to connect the furnace for a two-stage application.

Low Voltage Wiring

Furnace is factory conﬁ gured to operate on low and high ﬁ re – two stage mode conﬁ gurations. The second stage will function based on the program settings in the thermostat controller. The furnace integrated control board consists of two boards – main and add-on boards. The two boards are pre-wired with the furnace interface board. The IQ thermostat controller requires wiring to the interface board in the ﬁ eld (see Figures 22 and 25).

The furnace cabinet must have an uninterrupted, unbroken ground to minimize injury should an electrical fault condition occur. The controls used in this furnace require an earth ground to operate properly. Acceptable methods for grounding are electrical wire or conduit approved for electrical ground service. Do not use gas piping as an electrical ground.

IMPORTANT NOTE: The use of shielded cable is required for the connection to the thermostat controller. This wire is ﬁ eld supplied. Ground the shielded cable at the furnace end only on the grounding lug on the interface board bracket.

Page 26

Field Supplied

Fused Service

Panel

Black (Hot)

White (Neutral)

Green or Bare

(Ground)

Field Supplied

Panel Connector

Black White

Ground

Field Supplied Disconnect Within Sight of Furnace

Ground

Figure 21. Line Voltage Field Wiring

Black White

Field Line Voltage

Black White

Ground

Junction Box (may be internal or external to the furnace). These connections can be made in the field supplied disconnect at the furnace.

Wiring

Factory Line Voltage Wiring

1. Heating thermostat controller wiring

a. Two stage heating: (see Figure 22):

Programmable controller thermostat for the two stage heating should be wired as wiring diagram shown in Figure 22. On a call for ﬁ rst stage heat, inducer runs for 30 seconds pre-purge at high speed. The furnace will operate on low ﬁ re and both the inducer and main blower will operate at low speed. On a call second stage heat based on programmed timing or differential temperature, the furnace will operate at high ﬁ re and both inducer and main blower will operate at high speed.

b. Low ﬁ re only operation: To set low ﬁ re

only operation, program the second stage temperature higher than the desired room temperature (refer to Thermostat controller Instructions). If the furnace is operated permanently at low stage, disconnect the yellow wire on the “W2” terminals between the furnace add-on board and the interface board. (See Figure 24).

c. Outdoor Thermostat Function: If available on controller program.

2. Cooling controller thermostat wiring: (see Figure 23, 25 and cooling wiring dia-

gram).

Once ﬁ eld wired for heating, Connect “R”

and “C” black wires on the Interface control board to the two black wires from the outdoor unit contactor (see Figure 23). Also connect DX+ DX- and GRD terminals between the Interface board and the outdoor unit inverter with green, white and black wires as shown

in Figures 23 and 25. Cooling unit operates at the best optimized condition for the outdoor weather according to program in the thermostat controller.

The thermostat controller must not be installed on an outside wall or any other location where its operation may be adversely affected. Adverse effects include radiant loading from ﬁ replaces, sunlight, or lighting ﬁ xtures, and convective loading from warm air registers or electrical appliances.

START-UP AND ADJUSTMENTS

Prior to start-up, verify that:

1. The line voltage power leads are securely connected, that the polarity of the connections is correct, and that the furnace is properly grounded.

2. The thermostat wires (A, B, C and R) are securely connected to the correct leads on the terminal strip of the interface board. (R, DX+, DX- and Gnd. (See Figure 22.)

3. The gas line service pressure does not exceed 10.0 in. water column (0.36 psig), and is not less than 4.5 in. water column (0.16 psig) for natural gas. For LP gas the line service pressure must not exceed 14 in. water column (0.51 psig), and must not be less than 11.0 in. W.C. (0.40 psig).

4. The roll-out and vent safety manual reset switches are closed. If necessary, press the red button to reset a switch. See Figure 26 for location. DO NOT install a jumper wire across a switch to defeat its function. If a switch reopens on start-up, DO NOT reset the switch without identifying and correcting

Page 27

Furnace

Input

(Btuh)

60,000 19.75 115-60-1 127 103 12 14 15

80,000 19.75 115-60-1 127 103 12 14 15

92,000 19.75 115-60-1 127 103 12 14 15

110,000 22.50 115-60-1 127 103 12 14 15

Cabinet

Width

(in.)

Nominal

Electrical

Supply

Maximum

Operating

Voltage

Minimum

Operating

Volt ag e

Maximum

Furnace

Amperes

Minimum

Wire

Gauge

* Time-delay fuses or HACR-type circuit breakers are required.

Table 10. Electrical Data

Maximum

Fuse or Circuit

Breaker Amps*

the fault condition which caused the switch to trip.

5. The blower door is in place, closing the door switch in the line voltage circuit.

6. The gas line has been purged and all connections are leak tight.

Start-up Procedures

After all of the above checks have been made:

1. Close the disconnect(s) to provide line voltage to the furnace.

2. Set thermostat controller using the installer’s instructions (also refer to Table 1). Note: Allow thermostat controller to go through fan calibration routine. This will take 60 seconds switch the system mode to heat.

3. Set the thermostat controller above room temperature and verify the operating sequence. (See the Sequence of Opera- tion).

4. After the furnace has run for approximately ﬁ ve minutes, set the thermostat below room temperature and verify steps (8) through (11) of the Sequence of Operation.

Verifying and Adjusting Firing Rate

The ﬁ ring rate must be veriﬁ ed for each installation to prevent over-ﬁ ring the furnace.

IMPORTANT NOTE: The ﬁ ring rate must not exceed the rate shown on the furnace rating plate. At altitudes above 2000 feet it must not exceed that on the rating plate less 4% for each 1000 feet.

Follow the procedure below to determine the ﬁ ring rate.

1. Shut off all other gas ﬁ red appliances.

2. Start the furnace and allow it to run for at least three minutes.

INTERFACE BOARD

DX+

DX-

THERMOSTAT

GND

ROUTE WIRES THRU RING CORE

RED

YELLOW

WHITE

GREEN

Figure 22. Thermostat wiring in ﬁ eld

RH R

W1 H

C W2

A B GD OD ID

Page 28

3. Measure the time (in seconds) required for the gas meter to complete one revolution.

4. Convert the time per revolution to cubic feet of gas per hour using Table 11.

5. Multiply the gas ﬂ ow rate in cubic feet per hour by the heating value of the gas in Btu per cubic foot to obtain the ﬁ ring rate in Btu per hour. Example:

• Time for 1 revolution of a gas meter with

a 1 cubic foot dial = 40 seconds.

• From Table 14 read 90 cubic feet per

hour of gas.

• Heating value of the gas (obtained from

gas supplier) = 1040 Btu per cubic foot.

• Firing rate = 1040 x 90 = 93,600 Btuh.

6. Adjustments to the ﬁ ring rate can be made by adjusting the gas manifold pressure. See the High Altitude Application section for additional information of ﬁ ring rate at elevations above 2000 ft.

verify the manifold pressure setting required for your particular installation. To adjust the manifold pressure, remove the regulator cap and turn the adjusting screw clockwise to increase pressure or counterclockwise to reduce pressure. Note: Check both low and high inputs to the Table 1. Replace the regulator cap after adjustments are complete.

CAUTION:

Do not re-drill the burner oriﬁ ces. If the oriﬁ ce size must be changed, use only new oriﬁ ces.

WARNING:

To avoid electric shock, personal injury, or death, disconnect the electric power before performing any maintenance.

The manifold pressure for low and high inputs must be set to the appropriate value for installation (see Table 1). Refer to either Table 6 for natural gas or Table 7 for LP/propane gas to

OUTDOOR UNIT

INVERTER

YELLOW

OUTDOOR UNIT

CONTACTOR

GND DXDX+

CN11

BLACK

BLACKBLACK

BLACK

GREEN

WHITE

Selecting The Cooling Airﬂ ow Rate

The thermostat controller communicates with the outdoor unit to determine the proper airﬂ ow. The system will operate automatically at the optimum

RING

INTERFACE BOARD

RED

WHITE

GREENRED

24 VAC

TWIN

DX-

GND

O.D. UNIT

THRU CORE RING

TO L.V. BARRIER

THRU CORE

T1 T1

L1L1

Figure 23. Outdoor cooling unit

connection

Page 29

airﬂ ow rate for the capacity. Detailed operation is described in the cooling unit installation instructions and control manual.

Verifying and Adjusting Temperature Rise

Verify that the temperature rise through the furnace is within the range speciﬁ ed on the furnace rating plate. Temperature rises outside the speciﬁ ed range could result in premature heat exchanger failure.

Place temperature measuring device in the return and supply air stream as close to the furnace as possible. The device on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings. Adjust all registers and duct dampers to the desired position and run the furnace for ﬁ fteen minutes before taking any temperature readings. The temperature rise is the difference between the supply and return air temperatures.

Verifying Burner Operation

To verify operation of the burners, make sure that the blower compartment door is in place and that there is power to the furnace. Set

the thermostat above room temperature and observe the ignition sequence. The ﬂ ame can be observed through the small clear window on the burner box. The ﬂ ames should be blue, without yellow tips. Flames should extend from each burner without lifting, curling, or ﬂ oating. After verifying ignition, set the thermostat below room temperature and verify that the burner ﬂ ame extinguishes completely.

Verifying Operation of the Supply Air Limit Switch

To verify operation of the supply air limit switch, make sure that the blower door is in place and that there is power to the furnace. Completely block the return airﬂ ow to the furnace by installing a close-off plate in place of or upstream of the ﬁ lter(s). Set the thermostat above room temperature and verify that the Sequence of Operation is as described in these instructions. The supply air limit switch should function to turn off the gas valve within approximately ﬁ ve minutes. The circulating air and combustion blowers should continue to run when the supply air limit switch opens. Remove the close-off plate immediately after the supply air limit switch opens. If the furnace operates for more than ﬁ ve minutes with no return air, set the thermostat below room

TIME FOR

ONE REVOLUTION

(SECONDS)

24 150 750 1500 74 49 243 486 26 138 692 1385 76 47 237 474 28 129 643 1286 78 46 231 462 30 120 600 1200 80 45 225 450 32 113 563 1125 82 44 220 439 34 106 529 1059 84 43 214 429 36 100 500 1000 86 42 209 419 38 95 474 947 88 41 205 409 40 90 450 900 90 40 200 400 42 86 429 857 92 39 196 391 44 82 409 818 94 38 191 383 46 78 391 783 96 38 188 375 48 75 375 750 98 37 184 367 50 72 360 720 100 36 180 360 52 69 346 692 102 35 176 353 54 67 333 667 104 35 173 346 56 64 321 643 106 34 170 340 58 62 310 621 108 33 167 333 60 60 300 600 110 33 164 327 62 58 290 581 112 32 161 321 64 56 281 563 114 32 158 316 66 55 273 545 116 31 155 310 68 53 265 529 118 31 153 305 70 51 257 514 120 30 150 300 72 50 250 500

GAS FLOW RATE (CUBIC FEET PER HOUR)

CUBIC FEET PER REVOLUTION OF METER

1510 1510

TIME FOR

ONE REVOLUTION

(SECONDS)

CUBIC FEET PER REVOLUTION OF METER

Table 11. Gas Flow Rate

Page 30

temperature, shut off the power to the furnace, and replace the supply air limit switch.

DESCRIPTION OF COMPONENTS

Figure 26 shows the location of each of the functional components described below. If any component of the furnace must be replaced, use only factory authorized replacement parts. See the Replacement Parts List for each component.

Flame Sensor – The ﬂ ame sensor acts to prove that ﬂ ame has carried over from the igniter to the opposite end burner. If no ﬂ ame is sensed, the furnace will be shut down automatically.

Primary Gas Valve – The gas valve controls the ﬂ ow of gas to all of the burners. When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold.

Secondary Gas Valve – The gas valve controls the ﬂ ow of gas to the high ﬁ re burners only.

Pressure Switch – The pressure switch veriﬁ es that the inducer is drawing the combustion gases

through the heat exchanger. It also senses a blocked condensate drain condition.

Vent Pressure Switch – The vent pressure switch reacts to blockage in the vent or combustion air piping.

Supply Air Limit Switch – The supply air limit switch prevents the air temperature leaving the furnace from exceeding the maximum outlet air temperature.

Vent Safety Switch – The vent safety switch shuts the furnace down if the outlet ﬂ ue gas temperature increases above 160°F. This switch protects the plastic ﬂ ue system and the inducer from over-temperature conditions.

Flame Roll-Out Switch – This switch provides ﬂ ame roll-out protection to the furnace and combustion air inlet pipe.

MAINTENANCE

It is recommended that the furnace be checked yearly. At a minimum, this check should include the following items.

Optional Connector

120 VAC

Common

Leads

Connect

Neutral

Lead of

Electronic

Air Cleaner

and/or Humidifier

Here.

Y2Y2W2

41526

R C Y G W

EAC

HUM

Humidifier Tap

(.5A@ 120 VAC)

COM

24 V

Neutrals

ADD-ON BOARD

3 Amp Fuse

Main Board

Unused Motor

Leads

M1M2M3

HUM

Timing Switch

123

Flame Signal Light (Yellow)

Status

Light (Red)

COOL

HEAT

These motor speed taps are

not used for two-stage models

XFMR

EAC

Electronic Air Tap

(.5A@ 120 VAC)

Figure 24. Blower Speed Tap Location

Page 31

For 95+ 2-Stage Model Furnaces (2-Stage Inducer)

SWITCH

BLACK

WHITE

BLUE

BLU

BLOWER DOOR

SWITCH

FLAME ROLL-OUT

SUPPLY AIR

LIMIT SWITCH

TRANSFORMER

GREEN

SWITCH

PRESSURE

BLOCKED VENT

BLUE

SWITCH

PRESSURE

CONDENSATE

BLK W/ WHITE STRIPES

BLACK

ORANGE

LOW

WHITE

WHITE W/BLK STRIPES

120 V

BLACK

24 V

VENT SAFETY SWITCH

VIOLET

HI HI

FLAME STATUS

TWIN

3-PIN PLUG

3 2

6-PIN PLUG

ADD ON BOARD

NGE

ORA

BLA

456

GREEN

LOW

YEL

BRO

YELLOW

BROWN

RED

BLOWER OFF

3 AMP FUSE

24 V

COM

GREEN

FLAME SENSOR

9-PIN PLUG

BLA

XFMR

EAC

COOL

6-PIN PLUG

NEUTRALS

RED

HILOW C

HEAT

VIOLET

HUM

EAC

HUM

IGNITO

GAS

VALVE

PRIMARY

BLACK

WHITE

BLACKRED

3-PIN PLUG

WHITE

BLA

3-PIN HOUSING

BLA

(SUPPLIED W/ INDUCER)

INDUCER

2-PIN

HOUSING

FURNACE

BOARD

123

456

789

BRO

TEMP

BLACK

SENSOR

CABLE

CONTROL

PLUG

CONNECTOR

3-PIN HARNESS

RED

COIL

SENSOR

SUCTION TEMP.

BLACK

COIL

THERMISTOR

SENSOR

SUCTION PRESS.

MOTOR

BLACK

I.D. BLOWER

INTERFACE

THRU CORE

RED

POWER

3-PIN HARNESS

O.D. UNIT

DX-

DX+

GRD

RED

WHITE

GREEN

BOARD

RING

OUTDOOR

GREEN

RED

CABLE

U CORE

THR

UNIT

BLACK

WHITE

RING

CABLE

RED

YELLOW

DX+

HARNESS

WHITE

BLACK

GREEN

WHITE

DX-

345

GREEN

GND

THERMOSTAT

BUSHING

NOISE

FILTER

WHITE

BLACK

GREEN

RED

4-PIN

HARNESS

TWIN

OFF

SW1

THERM

SW2

THERM

EXV

BOARD

GREEN

CW2RHRW1H0Y2Y1GL

BLUE

WHITE

RED

BLUE

YELLOW

BLACK

GRAY

RED

YELLOW

EXV

COMM

6-WIRE CABLE

EXV

UNIT

OUTDOOR

ABGDODID

LEGEND:

THERMOSTAT

CONTROL

STATUS

RED LIGHT

FIELD WIRING

LOW VOLTAGE

HIGH VOLTAGE

NOTES:

1. Use copper conductors only.

2. If any of the original wires as supplied with the furnace must be replaced,

it must be replaced with wiring material having a temperature rating of at

least 105˚ C.

3. Refer to the Installation Instructions provided with the furnace for the

appropriate heating and cooling settings for your application.

4. Ensure that wires from the blower remain connected to the board thermo-

stat terminals after making the field thermostat connections.

FLAME

LIGHT

YELLOW

FAULT CONDITION

Flash

Continuous

Low Flame Sensor Signal

Flame Presen

OFF

Power On ON

Limit Circuit Open or External Load On "W" 1 FLASH

Pressure Switch is Open with Inducer On 2 FLASHES

Hi Pressure Switch is Open (Add-on board LED) 2 FLASHES

Pressure Switch is Closed with Inducer Off 3 FLASHES

Ignition Failure (Check Ground) 4 FLASHES

115 VAC & Neutral Reversed or no Ground 5 FLASHES

False Flame or Gas Valve Relay Shorted Continuous

Power Of

WD# 7106800

Figure 25. Wiring Diagram

Page 32

WARNING:

To avoid electric shock, personal injury, or death, disconnect the electric power before performing any maintenance.

further oiling of the bearings is required for the life of the motor.

Condensate Drain Assembly

Be sure the condensate lines are free and open (i.e. avoid kinking hoses). Also make sure all hose clamps are tight to avoid drawing air into the system.

WARNING:

Holes in the vent pipe or heat exchanger can cause products of combustion to enter the home. Replace the vent pipe or heat exchanger if leaks are found. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death.

Combustion Air and Vent System

Check the combustion air and vent pipe to ensure that it is not damaged, corroded or blocked by debris. Any damaged section of vent pipe must be replaced, and any obstruction or blockage must be removed prior to operating the furnace.

WARNING:

Never operate the furnace without a ﬁ lter in place. Dust and lint in the return air can build up on internal components, resulting in loss of efﬁ ciency, equipment damage, and possible ﬁ re.

Blower Compartment

The blower compartment should be cleaned monthly during the heating and cooling seasons to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor. Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and shortened service life.

Heat Exchanger and Burner Maintenance

The furnace should operate for many years without excessive soot buildup in the ﬂ ue passageways, however, the ﬂ ue passageways, the vent system, and the burners should be inspected and cleaned (if required) by a qualiﬁ ed serviceman annually to ensure continued safe operation. Particular attention must be given to identify deterioration from corrosion or other sources.

SYSTEM OPERATION INFORMATION

Proper maintenance is most important to achieve the best performance from a furnace. Follow these instructions for years of safe, trouble free operation.

• Do not place combustible materials on or against the furnace cabinet or the vent pipe.

Air Filter(s)

Air ﬁ lter(s) are not supplied with the furnace as shipped from the factory. Filters for side return and bottom return applications are available from your local distributor.

The installer should provide a ﬁ lter rack for a high velocity type ﬁ lter in the return air duct adjacent to the furnace. Filters should be changed or cleaned monthly during the heating season. New or newly renovated homes may require more frequent changing until the construction dust has been removed.

Lubrication

The bearings in the circulating air blower motors are pre-lubricated and sealed at the factory. No

• Do not store gasoline or any other ﬂ ammable vapors and liquids in the vicinity of the furnace.

• Change or replace the air ﬁ lters monthly during any period when the circulating blower is operating regularly.

• Always replace the doors on the furnace after servicing. Do not operate the furnace without all doors and covers in place.

• Avoid operating the furnace when windows and doors are open.

• Be sure that the thermostat is properly installed and is not being affected by drafts or heat from lamps or other appliances.

Page 33

Upﬂ ow/Horizontal Furnace Models

1 Igniter (Not Shown) 2 Flame Sensor (Not Shown) 3 Gas Valve 4 Flame Roll-out Switch(s) 5 Condensate Pressure Switch 6 Pressure Switch 7 Control Board 8 Add On Board

9 Blower Door Switch 10 Vent Safety Switch 11 Low Voltage Transformer 12 Supply Air Limit

Switch

13 Circulating Air Blower Assembly14 Induced Draft Blower 15 Condensate Drain Tube (Not Shown) 16 In-Line Drain Assembly 17 Burner View Port 18 Front Header Box 19 Combustion Air Intake (Not Shown) 20 Exhaust Vent 21 Variable Speed Blower Kit 22 Gas Manifold Assembly 23 Burner Box Assembly

Figure 26. Location of Major Components

Page 34

Sequence of Operation

The operating sequences for the heating, cooling, and fan modes are described below. Refer to the ﬁ eld and furnace wiring diagrams; Figures 22 and 25.

Heating Mode:

1. On a call for heat, the thermostat sends signal to the interface control applying 24 VAC to the interface board.

2. The control board checks for continuity on the 24 VAC limit control circuit (over-temperature limit switch, ﬂ ame rollout switches and blocked vent switch in series). If an open limit is detected the control board will energize the inducer blower. All other system functions will be inoperable until the limit circuit closes. While the limit is open, the bottom red LED will pulse at a rate of 1 blink per unit time.

3. The furnace control checks for continuity across the pressure switch (24 VAC). If the pressure switch is closed the heat mode sequence will not continue. If it remains closed for 10 seconds the red LED will blink 3 times repetitively until the fault condition clears. Note: Red LED light on the add-on board will ﬂ ash if vent high set pressure switch opens. Both red LEDs will ﬂ ash if lower set pressure switch opens also. If it closes, red LED on both the boards will reset automatically one hour later.

4. The inducer is energized.

5. The pressure switches for both high and low stages will close. If the pressure switches do not close after 10 seconds the fault LED will blink 2 times repetitively and inducer will continue to run until the switches are closed. Note: If the low stage pressure switch closes only, and T-Stat call for 2nd stage, red LED on the add-on board will ﬂ ash for an hour.

6. The inducer will pre-purge for 30 seconds at high speed and reduce to low speed. The igniter will start its warm up as follows:

Initial Power up: After 30 seconds of igniter

warm-up the gas valve (24 VAC) will then open. The igniter circuit will stay energized for 3 seconds after the gas valve opens.

After Initial Power up: The control has a

programmed adaptive ignition feature which varies the warm-up period as follows: If ignition is successful the warm-up is reduced by 3-seconds on each subsequent call for

heat until ignition failure occurs. Upon ignition failure, the warm-up is increased by 3-seconds on the next try. If successful, the timing remains ﬁ xed at this level. In general, whenever ignition failure occurs the warm-up interval is increased by 3-seconds on the next try. And if successful, it remains there. Minimum and maximum warm-up time limits are set at 6 and 54 seconds, respectively.

7. The furnace control must prove ﬂ ame via the ﬂ ame sensor 5 seconds after the gas valve opens. If ﬂ ame is sensed, all burners are on and the igniter cools off. If no ﬂ ame is sensed, the gas valve closes immediately and the inducer continues to run. A second trial for ignition (step 6) begins if no ﬂ ame is sensed on the ﬁ fth tr y for ignition, the fur nace control is locked and the red LED will blink 4 times repetitively. The thermostat must be off for at least ten seconds to reset the furnace control after a lock out. Otherwise, the furnace will attempt another ignition sequence in 1 hour.

8. The ther mostat sends a signal to the interface control to operate the blower at selected speed.

9. When the thermostat controller has been satisﬁ ed, high ﬁ re of the gas valve is deenergized and then operates back at low ﬁ re. Main blower stages to lower speed. Low ﬁ re is satisﬁ ed, the low ﬁ re will be deenergized.

10. The inducer is de-energized after a 30 second postpurge.

11. The circulating air blower remains on for 120 seconds.

12. Abnormal conditions: If a limit opens during operation, the inducer blower continues to operate. The gas valve is de-energized immediately. The inducer blower continues to operate until the limit closes, then is deenergized.

Cooling Mode:

1. On a call for cooling the thermostat sends a signal to the interface control to operate the blower and outdoor unit.

2. The circulation blower will then ramp to the selected airﬂ ow.

3. The system will modulate capacity and airﬂ ow rate to match the load requirements. If the temperature falls below the set point, the control will shut the system off.

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Fan Mode:

1. On a call for fan operation, the thermostat sends a continuous on signal to the blower.

2. The circulating air blower ramps to the programmed airﬂ ow rate for the FAN ON mode.

Furnace Fails to Operate

If the furnace does not operate check the following:

1. Is the thermostat operating properly?

2. Are the blower compartment door(s) in place?

3. Is the furnace disconnect closed?

4. Has the circuit breaker tripped or the control board fuse burned open?

5. Is the gas turned on?

6. Are any manual reset switches open?

7. Is the ﬁ lter dirty or plugged?

8. Is the ﬂ ame sensor coated? (Remove and clean with emery cloth.)

If the furnace locks out after 5 attempts for ignition, it will try again every hour if a call for heat remains.

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INSTALLATION/PERFORMANCE CHECK LIST

LOCATION ____________________________ CITY _____________________ STATE _______

INSTALLER ___________________________ CITY _____________________ STATE _______

UNIT MODEL # ________________________UNIT SERIAL # __________________________

Minimum Clearances per Table 3? _________

Electrical Connections tight? ______________

Line Voltage Polarity correct? _____________

Supply Voltage: ____________________ Volts

Blower Motor HP: _______________________

FUEL TYPE:

Natural Gas _______ LP/Propane _________

Gas Piping Connections leak-tested? _______

Gas Line Pressure: _____________________ (in. water column, with furnace operating)

Manifold Pressure: ______________________ (in. water column, with furnace operating)

Is there adequate fresh air supply for combustion and ventilation? ______________

Furnace Input: __________________ (Btuh)

Supply Air Temperature: ____________ (° F)

Temperature Rise: _________________ (° F)

Are Flue Connections tight? ______________

Is there Proper Draft? ___________________

Is Vent free from restrictions? _____________

Is the Filter(s) secured in place? ___________

Is the Filter(s) clean? ____________________

Has the Thermostat been calibrated? _______

Is the Thermostat level? _________________

Is the Heat Anticipator Setting correct? ______

Has the Owner’s Information been reviewed with the home-owner? _______________________

Has the Literature Package been left near the furnace? _____________________________

Return Air Temperature:_____________ (° F)

¢708766R¤

708766A

O’Fallon, MO

708766A (Replaces 7087660)

Speciﬁ cations and illustrations subject to change without notice and without incurring obligations.

Printed in U.S.A. (11/07)